032011
150 A TIG WELDING MACHINE
TIG150i
INTRODUCTION
The TIG150i is a 150A inverter-style AC/DC TIG welder that is used to weld both ferrous
and non-ferrous metals. The inverter technology is a smaller and therefore lighter package
size allows portability when needed or can also be placed onto a cart for traditional use
around the shop. Welding capabilities range from extremely thin up to 1/4ā on multiple
passes. The welder features ease-of-use for quick start-up in addition to multiple features
such as upslope, downslope, pulse and frequency adjustment or the most experienced
welder. Applications include automotive repair, collision repair, motorsports, manufacturing,
marine, aviation, agriculture and metal fabrication shops.
1
Introduction............................................................................................................................... Front Cover
Table of Contents ...................................................................................................................................... 1
Safety Information .................................................................................................................................. 2-3
Specifications ............................................................................................................................................ 4
Features .................................................................................................................................................... 5
Description of Equipment ....................................................................................................................... 6-9
Assembling the Unit/Start-up Guide ........................................................................................................ 10
TIG Welding ā Introduction.................................................................................................................11-12
- DC TIG Welding............................................................................................................................ 13
- AC TIG Welding.......................................................................................................................14-15
- Optional Foot/Remote Amperage Control .................................................................................... 16
Stick Arc Welding .................................................................................................................................... 17
Troubleshooting/Maintenance ................................................................................................................. 18
Replacement Parts ............................................................................................................................. 19-20
- Parts List....................................................................................................................................... 19
- Standard and Optional Accessories ............................................................................................. 20
Wiring Diagram........................................................................................................................................ 21
Warranty/Service and Repair .................................................................................................................. 22
TABLE OF CONTENTS
2
MUST READ INSTRUCTIONS BEFORE USE
Read, understand and follow all safety messages
and instructions in this manual. Safety messages in
this section ofthe manual contain a signal word with
a three-part message and, in some instances, an
icon.
The signal word indicates the level of the hazard in
a situation.
DANGER
Indicates an Imminently hazardous Situation which,
if not avoided, will result in death or serious injury to
the operator or bystanders.
WARNING
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury
to the operator or bystanders.
CAUTION
Indicates a potentially hazardous situation which, if
not avoided, may result in moderate or minor injury
to the operator or bystanders.
IMPORTANT
Indicates a situation which, if not avoided, may
result in damage to the welding equipment.
Safety messages in this section contain three
different type styles.
ā¢ Normal type states the hazard.
ā¢ Bold type states how to avoid the hazard.
ā¢ Italic type states the possible consequences of
not avoiding the hazard.
An icon, when present, gives a graphical
description of the potential hazard.
Arc Welding
DANGER
ā¢ Electric welding or plasma cutting cause ultra
violet rays and weld spatter
Bystanders will be exposed to ultraviolet rays
and weld spatter.
Wear welding helmet with appropriate shade
lens while using electric welders or plasma
cutters.
Do not allow bystanders while welding or
cutting.
Wear safety shield and protective clothing.
Ultraviolet rays will burn eyes; weld spatter can
cause injury.
WARNING
ā¢ Welding produces heat, sparks, hazard of
electric shock and/or hazardous vapors
Wear appropriate gloves, helmets or goggles
and other protective clothing.
Follow all instructions and safe practices while
welding or cutting.
Keep bystanders away from immediate area.
Byproducts of welding can cause burns or other
bodily injury.
SAVE THESE INSTRUCTIONS
SAFETY INFORMATION
3
Risk of Electrical Shock
WARNING
ā¢ Electrical shock can result when contacting
live electrode or internal components
ā¢ Electrical shock can result from absence of
grounding prong
Do not touch electrode or internal components
without protection.
Disconnect power before servicing.
Do not remove the grounding prong in any
electrical plug.
Electrical shock can cause injury
Risk of Explosion
WARNING
ā¢ Welding causes sparks that can cause
explosion
Use caution and proper procedures when
welding.
Avoid sparks if gasoline vapor and other fuels
are present.
Electrical shock, flames and explosion can cause
serious injury
Electrical and Magnetic Fields
WARNING
ā¢ Welding may cause localized Electrical and
Magnetic Fields around cables and power
sources
ā¢ The magnetic fields created by high currents
may affect the operation of medical
equipment.
Route the electrode and work cables together.
Do not place your body between the
electrode/torch and work cables.
Never coil the electrode/torch lead around
your body.
Do not work next to welding/cutting power
source.
Electrical shock and Magnetic fields can cause
injury.
Disposal of Equipment
IMPORTANT
ā¢ Disposal of electrical equipment can be
hazardous to the environment
Contact local regulations prior to disposal
Improper disposal can cause an environmental
hazard
SAFETY INFORMATION contād
4
By selecting TIG AC welding mode you may
weld
aluminum, aluminum alloys, brass and magnesium, while
selecting
TIG
DC allows you to weld steels,
stainless steel, iron and
copper
.
This welding machine is a direct and alternating
curr
ent
power source built using
INVERTER
technology, designed
to
weld covered electrodes
(not
including
cellulosic)
and for TIG
procedures, with contact starting and high
fr
equency
EXPLANATION OF THE TECHNICAL
SPECIFI
CATIONS
LISTED ON THE MACHINE PLATE.
NĀ°. Serial number, which must be indicated on any type of
request regarding the welding machine.
Single Phase
Downslope.
TIG/MMA Suitable for TIG/MMA welding.
U0. Secondary open-circuit voltage (peak value)
X. Duty cycle percentage. % of 10 minutes
during
which the welding machine may run at a
certain
current without overheating.
I2. Welding
curr
ent
U2. Secondary voltage with current I2
U1. Rated supply
voltage
1~ 50/60Hz 50- or 60-Hz single-phase power
supply
I
1
Max Max. absorbed current at the
corr
esponding
current I
2
and voltage U
2
.
I
1
eff This is the maximum value of the actual
curr
ent absorbed, considering the duty
cycle.
This value usually corresponds to the
capa
city
of the fuse (delayed type) to be used as a
protection for the
equipment.
IP23S Protection rating for the housing. Grade 3 as
the second digit means that this machine may
be stored, but it is not suitable for use
out-
doors in the rain, unless it is
pr
otected.
S
Suitable for hazardous
envir
onments.
SPECIFICATIONS+
Power+In put +
++
Voltage(
208/230(Volts(AC(
Phase((
Sin gle(Phase (
Fre quenc y(
50/60( Hertz(
Current(
30(Am ps(
Current(
15.8(Amps(
Power+Output+
++
Weld(Cur rent(Range(
5ā1 50(Am ps(
Duty(Cycle(@(100A((
100%(
(Duty(Cyc le(@(110A((
60%(
(Duty(Cyc le(@(150A((
30%(
Arc (Voltage(
14.5(V olts(
Output+Control+
++
On/Of f(Remote(
Sta ndard(
Foot(Pedal(
Optional(
Fin ger(Co ntrol((
Optional(
Pul se+Frequency+
0.16(ā150 Hz(
Background+Amp+Setting+
0ā1 50(Am ps(
AC+Wave shape+Balance+
++
Cle ani ng(
(1ā8(
Penetration(
(1ā8(
Frequency+
50(ā(15 0(Hz(
Pul se+Frequency+
0.16ā250( Hz(
Upslope+
0ā10(Seco nds(
Downslope+
0ā1 0(Seconds(
Post+Gas+
0ā3 0(Seconds(
Gas+Require ment+
100%(Argon(
Torch+Cable+Length+
25(Feet(
Ground+Cable+Length+
25(Feet(
Gas+Hose+Le ngth+
10(Feet(
Unit+Dimensions+
((
Height(
17"(
Width (
8"(
Depth (
17"(
Base+Unit+W eight+
37(lbs(
Shipping+Weight+
57(lbs(
SPECIFICATIONS
5
FEATURES
ā¢ 150 Amp AC/DC TIG Welder
ā¢ TIG weld most metals.
ā¢ MMA āStick Weldingā with optional cable
assembly.
ā¢ Inverter technology allows the welder to be
lightweight (37lbs.) and still able to perform
most welding applications.
ā¢ The adjustable amperage output of a minimum
of 5 amps, along with pulse technology, allows
welding of extremely thin materials.
ā¢ The maximum of 150 amps will weld most
applications up to Ā¼ā with multiple passes.
ā¢ Power Factor Correction āPFCā system only
requires a 30 amp 220 volt circuit saving
substantial electric cost. This also allows
increased input voltage tolerance of +15% to -
20%.
ā¢ High frequency start allows for easy arc
starting and can be turned off for scratch start if
needed.
ā¢ Scratch start feature if high frequency start is
not desirable.
ā¢ Adjustable upslope and downslope feature
helps to prevent burn through at the edge of
the material.
ā¢ Adjustable post gas prevents air from getting
to material before it cools.
ā¢ Pulsed arc for working even on thin sheets,
where the heat transferred must be kept to a
minimum.
ā¢ Tunnel design construction allowing an
exceptional cooling efficiency, keeping those
components that suffer in dusty environments,
such as electronic circuits, out of the cooling
flow.
ā¢ AC balance adjustment or penetration and
tungsten consumption control.
ā¢ Adjustable AC Frequency 50 - 150Hz for
precise heat output control.
ā¢ Background amperage adjustable from 5 to
150 amps DC and 10 to 150 amps AC.
ā¢ Remote foot control can be set for momentary
on or continuous on.
ā¢ Optional foot pedal or finger tip torch control
allowing precise amperage adjustment
between low amp and high amp setting.
ā¢ The TIG150i includes lightweight torch
assembly, ground cable, flow style regulator,
on/off control switch, installed gas hose, and
consumable tungsten kit. The only additional
start up purchases needed are the input plug
and welding gas.
ā¢ Exceptional technical support of over 30 years
of experience by calling 800 ABC WELD.
6
The LEDs
light alongside the
various
symbols to display your
choice:
F N M L Z Y J AA
G
B
C
D
AE
H
T
A
V
P
X
E
W
Q
U
R
S
O
AC AB
AD
DESCRIPTION OF EQUIPMENT
+
-
7
A - Procedure selector switch
(Left-hand ādown arrowā Key
This push-button selects the welding
pr
ocedur
e
(MMA or
TIG).When selected, one of the following LEDs
lights:
B C o r D
E Mode key. (Right-hand ādownā arrow key.)
When selected, one of the following LEDs
lights:
F, G,
H, L, M, N TIG mode there will always be two LEDs lit:
one indicating HF or striking start mode, the other
continuous or pulse mode in 2 or 4 stage.
F - LED. TIG welding with arc
started
without high
frequency.
To light the arc, press the torch trigger and touch the
tung
sten
electrode to the work piece, then lift it. This move
must
be
quick and decisive (0.3 sec.). Use this process when high
frequency is not permitted.
L ā LED TIG welding with arc started with high
frequency.
To light the arc, press the torch trigger: a high
voltage
fr
e
quency pilot spark will light the
ar
c.
G - LED. Continuous 2-stage TIG welding
(manual).
When the torch trigger is pressed, the current begins.
When
the
trig
ger is released, returns to zero. In this position, you
may connect the optional pedal control
acces
sory
(TIGINVFP).
H - LED. Continuous 4-stage TIG welding
(automatic).
This program differs from the previous one in that the arc is
both started and shut off by pressing and releasing the
tor
ch
trigger
.
M - LED. Pulsed 2-stage TIG welding
(manual).
When the torch trigger is pressed, the current begins.
When
the
trig
ger is released, returns to zero. In this position, you
may connect the optional pedal control
acces
sory
(TIGINVFP).
N - LED.
Pulsed
4-stage TIG welding
(Automatic)
This program differs from the previous one in that the arc is
both started and shut off by pressing and releasing the
tor
ch
trigger
.
The Pulsed welding feature varies the weld current from the
main welding current (Peak Amperage ā high heat) and the
second level of welding or base current (Background
Amperage ā low heat) levels. The TIG150i has two (2)
different weld settings for the pulse features 2-stage TIG
welding (manual) M ā LED or 4-stage TIG welding
(automatic) N - LED.
The Pulse frequency is adjustable from .16 to 250 pulses
per second by selecting the mode U and setting the value
with the knob AA. The duration of total time āonā between
āHigh heatā and āLow heatā are equal.
āLED T ā ā Main welding current (Peak Amperage ā high
heat)
This value is usually set somewhat higher than it would
be set for a non-pulsed weld.
āLED V ā ā Second level of welding or base current
(Background Amperage ā low heat)
This of course would be set lower than Main welding
current. This value cannot be higher than the Main welding
current. Once the base current V is set (a percentage in
respect to the main current is established), so this value will
change automatically when increasing or decreasing the
Main current T .
āLED U ā ā Pulse frequency (Pulses per Second .
16 ā 250 HZ) Is the number of times per second that the
welding current achieves main welding current (Peak
Amperage ā high heat).
Some of the advantages:
ā¢ Good Penetration with less heat input to material
āburn throughā.
ā¢ Less distortion.
ā¢ Good control of the pool when welding out of
position.
ā¢ Ease of welding thin materials.
ā¢ Ease of welding materials of dissimilar thickness.
ā¢ Helps weld training.
ā¢ Smaller bead profile.
ā¢ Smaller heat-affected zone.
DESCRIPTION OF EQUIPMENT contād
8
J - LED - THERMAL PROTECTION
Lights when the operator exceeds the duty cycle or
per
cen
tage intermittence admissible for the machine, and
simulta
neously blocks the current
output.
NOTE: In this condition the fan continues cooling
the
power source.
Y - LED
This LED must always be lit to ensure safe
welding
conditions in AC
mode.
AA - KNOB
Adjusts the welding
curr
ent. (LED ā T)
Also, in
combination with the push-button P,
you
may:
- adjust the second level of current LED V
-adjust the "slope up" LE D S
-adjust the "slope down" L E D W
- adjust the pulse frequency LED
U
-adjust the post gas LED X
-adjust the current frequency in AC welding LED Q
-adjust the wave balance in AC welding LED R
- adjust the arc striking in relation to the diameter of the
elec
trode used in TIG AC mode
LED
O .
P ā
SELECTOR (Right Arrow)
When this button is pressed, the LEDs light in
suc
cession:
Q - LED
Current frequency in AC welding (50 - 150 Hz).
Current Frequency Control is enabled only in AC
TIG. Use this control to set the AC frequency
(cycles per second).
Current frequency controls bead width and
directional control. As AC frequency decreases,
weld bead/puddle gets wider. As AC frequency
increases, weld bead/puddle becomes narrower
and the arc becomes more focused. Travel speed
can increase as frequency increases.
R - LED
Wave
balance in AC welding
(balance
= 0; Cleaning
= from 1 to 8, flashing; Penetration = from 1 to 8,
not flashing).
The Wave Balance R feature makes it possible to
vary the half cycles of the square wave when
working in TIG AC when welding aluminum alloys.
The point where the two half-waves meet is zero.
The TIG150i offers 3 positions, Balanced, Cleaning
and Penetration.
Penetration (electrode negative) ā is when the
Wave Balance R is set clockwise from the ā0ā
position with non-flashing numbers betweenā1 - 8ā
on the display Z . This is set to produce the more
time at electrode negative and the minimum time at
electrode positive.
This adds the following benefits:
ā¢ Can use higher currents with smaller electrodes.
ā¢ Increased penetration at a given amperage and
travel speed.
ā¢ Use of smaller gas cup and reduced shielding gas
flow rate.
ā¢ Reduced heat input with smaller heat effected zone
and less distortion.
Balanced (zero) ā is when the Wave Balance R is
set to ā0ā position on the display Z . This position is
set to produce equal amounts of time electrode
negative (penetration) and electrode positive ). This
will give you less current absorption, reduced
electrode consumption and an ideal ratio between
the width and depth of the welding bead.
Cleaning (electrode positive) ā is when the Wave Balance
R is set counter-clockwise from the ā0ā position flashing
numbers between ā1 - 8ā on the display Z . This is set to
produce more time at electrode positive and the minimum
time at electrode negative. This adds the following benefits:
ā¢ Removes more surface oxides from the plate but
reduces electrode life.
O ā Led Displays the electrode diameter. The choice
of
electr
o
de
diameter ranges from 1mm to 4mm (.040 ā
5/32ā). Use the knob
AA
to
change the diameter. This
function is active only for AC
TIG
welding.
DESCRIPTION OF EQUIPMENT contād
9
S - LED
Slope up. This is the time in which the
cur
rent, starting from the minimum,
reaches
the
set current value. (0-10 sec.)
Slope Up can be used to assist in preheating cold material
prior to depositing filler material, or to ensure a soft start on
higher amperage settings.
T - LED
Main welding current. (10-130A in MMA
and
5-
150A in TIG)
V - LED
Second level of welding or base current. This
curr
ent
is always a percentage of the main.
Pulsed 2-stage or Pulsed 4-stage only - Use the
Second level of welding or base current to set
the low current pulse of the weld amperage,
which cools the weld puddle and affects overall
heat input. This current is always a percentage
of main current.
U - LED
Pulse frequency (0.16-250 Hz) The peak and
base times are equal. These pulses and the
base current level -V- between them (called the
Second level of welding ) alternately heat and
cool the molten weld puddle. The combined
effect gives better control of penetration, bead
width, undercutting, and heat input
W - LED
Slope down. This is the time in which the
cur-
rent reaches the minimum value and the
ar
c.
Slope Down should be used while
welding materials that are crack sensitive,
and/or to eliminate the crater at the end
of the weld.
X - LED
Post gas. Adjusts the time gas flows after
welding
ends. (0-30 sec.) Post Gas is required to cool the
tungsten rod and weld puddle, and to prevent
contamination of tungsten and weld. Increase post gas
time if tungsten or welds have a dark appearance.
Note: only those LEDs that refer to the chosen
welding
mode will light; i.e., in continuous TIG welding the LED
U
,
representing the pulse frequency, will not
light.
Each LED indicates the parameter that may be adjusted
by
means of the knob
AA
while the
LED
itself is lit.
Five
seconds
after the last variation, the LED involved will shut off;
the
main welding current will be displayed, and the
correspon
ding LED T
lights.
AE - 10-PIN CONNECTOR
The
following remote controls
are
connected to
this
connector:
a)
foot
contr
ol or on/off button.
b) torch with start
button.
c) torch with variable amperage device.
General Notes
Make sure the
insula
tion of the cables, electrode clamps,
sockets and plugs are intact, and that the size and length of
the welding cables are compatible with the current used.
AB - Negative output terminal
Plug the TIG torch in here.
AC -Positive output terminal (+).
Plug the āgroundā cable in here.
AD - 1/4 GAS OUTLET FITTING
DESCRIPTION OF EQUIPMENT contād
10
INSTALLATION
Make sure that the supply voltage is 230 volt and a minimum
of 30 amp service. When mounting a plug, make sure it has
an adequate
capa
city, and that the "yellow/green
conductor" of the power
supply cable is connected to the
ground or āearthā terminal. The blue and brown wires need
to be connected to the āhot legā terminals
WARNING
Only skilled personnel should install the machine. All
connections must be carried out according to current
regulations.
See complete listing of safety messages at the beginning of
this manual.
TORCH HEAD ASSEMBLY
1. Select the size tungsten electrode to be used
ā see table A
2. Make sure the Teflon heat shield is in place.
3. Locate the matching size Collet and Collet body.
4. Drop the Collet, slit-end down, into the Collet body.
5. Screw assembly into the torch head, heat shield side,
and tighten firmly.
6. Install a Gas cap, screw into place seating the cup
against the Teflon heat shield.
7. Insert tungsten electrode, prepped end first, thru the
torch head, Collet and center hole of the Collet body.
8. Allow tungsten electrode to extend past the cup ~ 3
times the electrode diameter.
9. Screw Backcap into torch head and tighten firmly.
Review the exploded view on the next page.
ASSEMBLING THE UNIT/START UP GUIDE
For detailed machine start up see
āSETTING UP YOUR NEW
TIG WELDING SYSTEMā.
11
TIG WELDING ā GENERAL
aluminum, aluminum alloys, brass and magnesium, while
stainless steel, iron and copper.
1. Connect the earth (work) cable connector to the
positive pole (+) (AC) of the welding machine, and
the clamp to the work piece as close as possible to
the welding point, making sure there is good
electrical contact.
2. Connect the power connector of the TIG torch to the
negative pole (-) (AB) of the welding machine.
3. Connect the foot pedal or on/off switch control plug
to the welding machine connector AE.
4. Connect the torch gas hose fitting to the gas outlet
fitting AD on the machine, and the gas hose from
the cylinder pressure regulator to the gas fitting AG
on the rear panel.
AF ā switch
Turns the machine on and off.
0 = Off l = On
AG - gas inlet fitting
DANGER
Do not touch
live
parts and output terminals while the
machi
ne
is
power
ed.
Read complete listing of safety messages at the beginning
of this manual.
1. The first time the machine is turned on, select the
pr
ocess
and mode using the push-buttons A and E ,
and the
welding
parameters by means of the key P and
the knob AA .
2. The type and diameter of the electrode to be used must
be
selected according to table A:
TABLE A
Inches/mm
DC
AC
(frequency 50/60
Hz)
Pos. Max Penetration
Pos. Balanced zero
Pos. Max Cleaning
Electrode
T
y
pe
.
T
ungsten
Thorium
2%
Red
T
ungsten
Pur
e
G
r
een
T
ungsten
Zr
0,8%
White
T
ungsten
Pur
e
Gr
een
T
ungsten
Zr
0,8%
White
T
ungsten
Pur
e
Gr
een
T
ungsten
Zr
0,8%
White
1/16in 1.6mm
70A ā 150A
50A ā 100A
70A ā 150A
30A ā 60A
50A ā 80A
20A ā 40A
30A ā 60A
3/32in 2.4mm
150A ā 250A
100A ā 160A
140A ā 235A
60A ā 120A
80A ā 140A
40A ā 100A
60A ā 120A
1/8in 3.2mm
200A ā 350A
150A ā 210A
225A ā 325A
80A ā 160A
100A ā 180A
60A ā 140A
80A ā 160A
5/32in 4mm
300A ā 400A
200A ā 275A
300A ā 400A
100A ā 240A
150A ā 280A
80A ā 200A
150A ā 250A
TIG WELDING - INTRODUCTION
AF
AG
By selecting
the
TIG AC
welding mode
you may weld
selecting TIG DC allows you to weld steels,
12
TIG WELDING ā INTRODUCTION contād
3. The flow of inert gas must be set to a value of 20-25
CFH. If you are using gas-lens type accessories, the gas
throughput may be reduced.
4. The diameter of the ceramic nozzle must be 4 to 6 times
the diameter of the electrode
5. Use D.I.N. 10 protective glasses for up to 75A, and D.I.N.
11 from 75 A up.
13
TIG Welding DC Basic Setup
ā¢ With High Frequency Start
ā¢ Using the On/Off Switch
Push the procedure selector switch (Left Hand Down
Arrow). This push-button selects the welding procedure
(MMA or TIG). When selected, one of the following LEDs
lights:
B , C , or D
Push the button until the TIG DC LED lights .
Then push the Mode Key E (Right Hand Down Arrow).
When selected, one of the following LEDs lights:
F,G,H,L,M,N. Continue to push the button until the L LED
lights along with the G LED.
L - LED. TIG welding with arc started with
high frequency.
G LED. Continuous 2-stage TIG welding
(manual).
P - SELECTOR (Right Arrow)
When this button is pushed, the following LEDs light in
succession:
S - LED
Slope up. This is the time in which the current, starting from
the minimum, reaches the set current value. (0-10 sec.)
AA ā Knob
Adjusts the slope up time while watching the Z display.
Z ā Display
Displays the settings selected.
Set the slope up to ā0ā seconds.
Push the P ā Selector (Right Arrow) until the T ā
LED main welding current display lights.
(10-130A in MMA and 5-150A in TIG)
Turn the AA knob while watching the Z display.
Z DISPLAY
Adjust the display to the required main welding amperage.
Rule of Thumb: ā1 amp per .001 of plate thickness. (.125 =
~125 amps)
** May require multiple passes.
Push the P ā Selector (Right Arrow) until the W ā
LED main welding current display lights.
W - LED
Slope down. This is the time in which the current reaches
the minimum and the arc shuts off. (0-10 seconds).
Turn the AA -Knob watching the Z - Display.
Set the slope down to ā0ā seconds.
Push the P ā Selector (Right Arrow) until the X ā
LED post gas display lights.
Post Gas Adjusts the time gas flows after the welding
ends. ( 0-30 seconds)
Turn the AA - Knob watching the Z - Display.
Set the post gas to ā10ā seconds.
Basic TIG DC Setup is Complete.
DC TIG WELDING
**
**
14
TIG AC Welding Mode Basic Setup
ā¢ With High Frequency Start
ā¢ Using On/Off Button
Push the procedure selector switch (Left Hand Down
Arrow). This push-button selects the welding procedure
(MMA of TIG). When selected, one of the following LEDs
lights:
B , C , or D
Then push the Mode Key E
(Right Hand Down Arrow).
When selected, one of the following LEDs lights:
F,G,H,L,M,N. Continue to push the button until the L LED
lights along with the G LED.
L - LED. TIG welding with arc started with
high frequency.
G LED. Continuous 2-stage TIG welding
(manual).
Push the P ā Selector (Right Arrow) until the Q ā
LED current frequency display lights.
adjusted from 50 ā 150 Hz.
Turn the AA - Knob watching the Z - Display.
Set the current frequency to ā60ā Hz.
Push the P ā Selector (Right Arrow) until the R ā LED
wave balance display lights.
R - LED
settings, balance = 0; Cleaning from 1-8, Penetration from
1-8.
Turn the AA - Knob watching the Z - Display.
Set the wave balance to the ā0ā position.
Push the P ā Selector (Right Arrow) until the O ā
LED electrode diameter display lights.
Displays the electrode diameter. The choice of
electrode diameter ranges from 1mm to 4mm.
Turn the AA - Knob watching the Z - Display.
Set the electrode diameter to the size recommended in
Table āAā. EX.(3/32ā = 2.4 mm).
Push the P ā Selector (Right Arrow) until the S
ā LED slope up display lights.
S - LED
Slope up. This is the time in which the current, starting from
the minimum, reaches the set current value. (0-10 sec.)
AC TIG WELDING
Push the button until the TIG
D
LED lights .
Current frequency in AC welding mode. Can be
Wave balance in AC welding. There are three possible
15
Turn the AA -Knob watching the Z - Display.
Set the slope up to ā0ā seconds.
Push the P ā Selector (Right Arrow) until the T ā
LED main welding current display lights.
(10-130A in MMA and 5-150A in TIG)
Turn the AA knob while watching the Z display.
Z DISPLAY
Adjust the display to the required main welding amperage.
Rule of Thumb: ā1 amp per .001 of plate thickness.
(.125 = ~125 amps)
Use the following as a guide for
setting up the amperage:
** May require multiple passes.
Push the P ā Selector (Right Arrow) until the W ā
LED slope down display lights.
W - LED
Slope down. This is the time in which the current reaches
the minimum and the arc shuts off. (0-10 seconds).
Turn the AA - Knob watching the Z - Display.
Set the slope down to ā0ā seconds.
Push the P ā Selector (Right Arrow) until the X ā
LED post gas display lights.
Post Gas Adjusts the time gas flows after the welding
ends. ( 0-30 seconds)
Turn the AA - Knob watching the Z - Display.
Set the post gas to ā10ā seconds.
Basic TIG AC Setup is Complete
AC TIG WELDING contād
**
**
16
How to Setup the Optional Variable Amperage Foot Pedal or
Remote Finger Amp Control (RAD).
ā¢ Using High Frequency Start
ā¢ TIG AC Mode
The Foot Pedal allows the welder to remotely control the
amperage from 5 amps minimum to 150 amps maximum
shown on the LED Z display.
Install the Foot Pedal or RAD control plug in the AE
receptacle.
Push the procedure selector switch (Left Hand Down
Arrow). This push-button selects the welding procedure
(MMA or TIG). When selected, one of the following LEDs
lights:
B , C , or D
Then push the Mode Key E
(Right Hand Down Arrow).
When selected, one of the following LEDs lights:
F,G,H,L,M,N. Continue to push the button until the L LED
lights along with the G LED.
L - LED. TIG welding with arc started with
high frequency.
---NOT AVAILABLE IN THE MMA MODE
G LED. Continuous 2-stage TIG welding
(manual).
Push the P ā Selector (Right Arrow) until the T ā
LED main welding current display lights.
(10-130A in MMA and 5-150A in TIG)
Activate the foot pedal or RAD to the maximum (pedal or
slider fully depressed) position.
While holding down the pedal to maximum,
turn the AA knob while watching the Z display.
Z DISPLAY
Adjust the amperage to the approximate current that is
required using the basic rule of thumb āone amp per
thousandths of material thickness. Ex. 1/8ā inch = .125
thousands so set the amps to ~125.
Push down on the pedal or slide the RAD.
ļ¶ The gas should purge.
ļ¶ High frequency should activate.
ļ¶ Amperage on the display Z should range from
5 to 125 amps.
NOW BEGIN TO WELD.
OPTIONAL FOOT PEDAL/
REMOTE AMPERAGE CONTROL
Push the button until the TIG AC LED lights .
17
MMA WELDING (MANUAL METAL ARC OR STICK WELDING)
DC (10-130 Amps)
- Make sure that the switch
AF
is in position 0, or āoffā position then
connect
the welding cables, observing the polarity
required by
the
manufacturer of the electrodes you will be using; also
con
nect the clamp of the ground cable to the work
piece, as close to the weld as possible, making sure that there is
good
electrical
contact.
WARNING
Do
NOT
touch the electrode clamp simultaneously with
the
earth
clamp.
Read complete listing of safety messages at the beginning of this manual.
1. Turn the machine on to ālā using the switch
AF
.
2. Select the MMA procedure by pressing the button
A
LED
B
lit.
3. Adjust the current based on the diameter of the
electr
o
de,
the welding position and the type of joint to be made.
- Always remember to shut off the machine and remove the electrode from the clamp after welding.
STICK ARC WELDING
18
DESCRIPTION OF PROTECTIVE DEVICES
Thermal protection
This machine is protected by a temperature probe,
which
prevents the machine from operating if the allowable
tempe
ratures are exceeded. Under these conditions the fan
keeps running and the LED J
lights. The duty cycle of the
welder has been exceeded if the welder overheats.
Duty cycle of a welding power source is the percentage
of a ten minute period that the welder can operate without
causing harm to the welder. Ex. A 60% duty cycle means
that the welder can operate for 6 minutes and should cool
for 4 minutes.
Block Protections
This welding machine is equipped with various safety
devi
ces
that stop the machine before it can suffer damage.
In the event of a malfunction, the letter E may appear
on
the
display Z , followed by a flashing
number:
52 = Start button pressed during
startup.
53 = Start button pressed during thermostat reset. In both
cases, release the start
button.
The machine stop is signaled by the flashing LED J
.
When this occurs, it signals:
1) During the start-up p ha s e, the power status of
the
machine.
2) After the start-up phase, incorrect supply
voltage.
3) With the machine running, that the voltage has fallen
below 118V.
4) With the machine running, that the supply voltage is above
280V.
5) During welding, that the voltage exceeds 300V.
switch, wait 5 seconds, and switch it on again. If the
pr
oblem
has
been corrected, the welding machine will begin
opera
ting
again.
NOTE: If the
supply
voltage is below 170V at start-up, no LED
will light and the fan is
power
e
d.
If the message E2 appears on the display, the machine
requires technical service. 800-ABC-WELD
TIG WELDER MAINTENANCE
Any maintenance operation must be carried out by qualified
personnel.
GENERAL TIG WELDER MAINTENANCE
In the case of maintenance inside the machine, make sure
that the switch AF is in position "O" and that the power cord
is disconnected from the mains. It is also necessary to
periodically clean the interior of the machine from the
accumulated metal dust, using compressed air.
PRECAUTIONS AFTER REPAIRS.
After making repairs, take care to organize the wiring so that
there is secure insulation between the primary and secondary
sides of the machine. Do not allow the wires to come into
contact with moving parts or those that heat up during
operation. Reassemble all clamps as they were on the original
machine, to prevent a connection from occurring between the
primary and secondary circuits should a wire accidentally
break or be disconnected.
Also mount the screws with geared washers as on the original
machine.
TROUBLESHOOTING/MAINTENANCE
To restore operation, check the voltage.
Then
shut off the AC
19
REPLACEMENT PARTS ā PARTS LIST
WHEN ORDERING SPARE PARTS PLEASE STATE THE MODEL NUMBER AND
SERIAL NUMBER AND PART NUMBER NEEDED.
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